Problem with scooter after theft

[oriel dave]

Hi, a while back my girlfriend's scooter (MBK Mach G (Yamaha Jog)) got stolen and recovered and they wrecked the ignition switch and the steering lock. They also nicked the battery! So I've fitted a pattern ignition switch and battery and the problem is this:

In the switch ON position the instrument panel is meant to light up and you can start it with the electric start, but I'm getting no power to any of the instruments. You can, however kick start it and then once its running all electrics work as normal (panel lights on etc.) and it runs fine.

In the ON position the ignition switch is getting 12V from the battery and from the wiring diagram if the ignition switch has 12V then so should the instruments. Also if there was a bad earth it would also affect the instruments when the bike's running. Very occasionally (in ON position) the instruments will flick on and off and once I was able to start it with the button. I have checked battery voltage and operation of ignition switch by checking voltages. I have also looked all over for damaged wiring etc.

One thing is that the ignition switch is supposed to have four settings:

LOCK - OFF - CHECK - ON

where in CHECK you just get the oil warning light I think, then in ON you get clocks, instrument lights etc. all on. But the pattern switch doesn't seem to have the CHECK position. Could this be causing problems even though the switch is behaving in ON?

Aside:

The steering lock is a little bit that pokes out of the ignition switch into the frame and they've damaged where it goes into the frame so it does lock but you can still move the bars 90degrees in LOCK position. I can't see how this could be related. I've also replaced starter relay, main fuse housing, and some cut connections but again I don't see how any of these could be causing any problems.

Thanks,

Dave
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Europe Trip 2009